Fuel Tank: Service and Repair

Fuel Tank Replacement

Removal

1. Relieve the fuel pressure.
2. Remove the fuel fill cap.
3. Drain the fuel tank: Remove the fuel tank unit. Using a hand pump, hose, and container suitable for gasoline, draw the fuel from the fuel tank.




4. Remove the trunk floor and the access panel (A) from the floor. Disconnect the fuel tank 5P connector (B).
5. Loosen the rear wheel nuts slightly, then raise the vehicle and make sure it is securely supported. Remove the rear wheels.
6. Release the parking brake.
7. Remove the catalytic converter.




8. Remove the fuel line cover (A). Disconnect the fuel fill neck tube (B), the fuel tank vapor recirculation tube (C) and the fuel tank vapor control signal tube (D) from the fuel fill lines (E).




9. Disconnect the fuel tank vapor vent tube (A) and the quick-connect fittings (B). Disconnect the hose (C). Remove the hose from the line holder (D). Disconnect the hose (E) from the EVAP two way valve (F). Remove the line holder (G).




10. If the vehicle has ABS, disconnect the wheel sensor 2P connectors (A); if not, go to step 11.

Fuel Tank:

11. Remove the stabilizer bar (A), the heat shield (B) and the parking brake cable bracket (C).

Fuel Tank:

12. If the vehicle has rear drum brakes, go to step 14 If it has rear disc brakes, remove the clip (A) and parking brake cable (B), two caliper bolts (C), caliper body (D), and brake hose bracket (E).




13. Hook the caliper body (A) on to the damper spring (B). Go to step 16.

Fuel Tank:

14. Disconnect the brake line (A) from the wheel cylinder (B).




15. Remove the brake drum and brake shoes. Remove the two mounting bolts for the parking brake cable from the backing plate, then remove the parking brake cable using a 12 mm offset wrench.




16. Remove the flange bolt (A).

Fuel Tank:

17. Place a jack or support under the rear suspension sub frame. Remove the mounting bolts (A) (4 cylinder: four bolts; shown, V6: 12 bolts; not shown). Remove the rear suspension sub frame.




18. Remove the bolts (A) and the fuel tank straps (B).
19. Remove the lines from the fuel line holder (C).
20. Lift the fuel tank out of the sub frame.

Installation

Fuel Tank:

1. Install the fuel tank straps (A), and tighten the bolts (B). Install the lines to the fuel line holder (C).




2. Place the jack, or support, under the rear suspension sub frame. Install the rear suspension sub frame, aligning the pins (A) with the holes in the rear suspension sub frame.
3. Install the remaining parts in the reverse order of removal.
4. If equipped with drum brakes, bleed the brake system after installing the brake hose. If not, go to step 5.
5. After installation, adjust the wheel alignment.